0303 Steel for making pipe molds

ABSTRACT

A low alloy steel, designated 0303 (Khare V) steel, that may be used for making pipe molds with high hardenability, high ductility and high toughness are described, the steel consisting essentially of from about 0.16% to about 0.22% carbon, about 1.00% to about 1.50% manganese, about 1.15% to about 1.45% silicon, about 0.015% maximum phosphorus, about 0.015% maximum sulfur, about 0.80% to about 1.10% chromium, about 0.20% to about 0.30% molybdenum, about 0.50% maximum nickel, about 0.03% to about 0.08% vanadium, and balance essentially iron.

TECHNICAL FIELD

[0001] The present invention relates to a ferritic alloy steel used for making pipe molds.

BACKGROUND OF THE INVENTION

[0002] Traditionally, low alloy steels like AISI 4130 (1% chromium, 0.20% molybdenum) and 21CrMo10 (2.25% chromium, 0.35% molybdenum) are considered the workhorse grades for pipe mold steel. The chemistry of these two grades, listed as weight percentages, is provided in Table 1, below. AISI 4130 chemistry is provided from Aerospace Structural Metals Handbook, (1986), pp 1-20. 21CrMo10 chemistry is provided from Stahlschlussel (Key to Steel) (1977), pp 192-207. These low alloy steels have been used quite successfully over the years. However, the restrictions on the minimum amounts of certain elements have limited the specific minimum hardenability, as well as the mechanical properties of tensile and impact that can be achieved from either of these grades. TABLE 1 Element AISI 4130 21CrMo10 Carbon 0.28-0.33 0.16-0.23 Manganese 0.40-0.60 0.20-0.40 Silicon 0.20-0.35 0.20-0.40 Phosphorus 0.025 Maximum 0.025 Maximum Sulfur 0.025 Maximum 0.025 Maximum Chromium 0.80-1.10 2.30-2.60 Molybdenum 0.15-0.25 0.30-0.40 Nickel 0.25 Maximum — Copper 0.35 maximum — Iron Balance Balance

[0003] Conventional thinking has been that pipe mold service life is primarily dependent on the properties of hardness and strength of the as-heat treated pipe mold. The main element in ferritic alloy steels that imparts hardness and strength to pipe mold steels is carbon. Therefore, it has been thought that to create pipe molds with long service lives there had to be high levels of carbon in the steel. Consistent with this thinking, the AISI 4130 grade had high carbon levels in the range of 0.28-0.33%.

[0004] Modifications to the AISI 4130 grade chemistry have been previously made in assignee's U.S. Pat. No. 4,992,239. There also have been improvements to the 21CrMo10 grade chemistry by the addition of vanadium.

[0005] There remains the need to produce pipe molds with properties that enhance the hardenability, while maintaining the strength, ductility and toughness under many types of working conditions. Additionally, this high strength and high hardenability can not be achieved at the expense of weldability in this steel.

SUMMARY OF THE INVENTION

[0006] The present invention relates to a ferritic alloy steel with high hardenability, high toughness, and high ductility for making pipe molds used for centrifugally casting pipe. The steel of the present invention may preferably be used to make pipe molds or other products undergoing high thermal stresses. Another object of the invention is to provide a steel for producing pipe molds with improved service life for centrifugally casting pipe. A further object of the invention is to provide a steel for producing pipe molds with improved service life for centrifugally casting pipe, with the pipe mold steel having a reduced carbon level and vanadium, manganese and silicon. Another object of the invention is to produce a steel of substantially high hardenability with the addition of manganese and silicon to the alloy system.

[0007] These and other objects of the invention will be described in detail in the remainder of the specification.

DETAILED DESCRIPTION OF THE INVENTION

[0008] The present invention is directed to a low alloy ferritic steel for making pipe molds with improved service life that are used for centrifugally casting pipe. Pipe molds made from this steel can be used to centrifugally cast both small and large diameter pipe. The steel preferably may be used to make pipe molds or other products undergoing high thermal stresses. The present invention relates to a steel with high hardenability, high toughness, and high ductility. This invention creates an alloy that is a modification of the AISI 4130 alloy system.

[0009] The alloying elements manganese and silicon, together with phosphorus, sulfur, chromium, molybdenum, nickel, and vanadium, provide desirable properties for long service life of pipe molds made with this steel. The combined effect of the use of manganese and silicon within the specified ranges, coupled with the other elements, promotes the enhancement of properties in the low chromium steel. The weight percentages of the steel of the present invention, which has been designated “0303” (Khare V), are set forth in Table 2, below: TABLE 2 Element 0303 (Khare V) Carbon 0.16-0.22 Manganese 1.00-1.50 Silicon 1.15-1.45 Phosphorus 0.015 Maximum Sulfur 0.015 Maximum Chromium 0.80-1.10 Molybdenum 0.20-0.30 Nickel 0.50 Maximum Vanadium 0.03-0.08 Iron Balance

[0010] The typical melt chemistry aims in weight percentages of the various elements is set forth in Table 3 below: TABLE 3 Element 0303 (Khare V) Carbon 0.18 Manganese 1.25 Silicon 1.25 Phosphorus as low as possible, 0.005 Maximum Sulfur as low as possible, 0.005 Maximum Chromium 0.90 Molybdenum 0.25 Nickel 0.30 Vanadium 0.05 Iron Balance

[0011] Moreover, the alloying of the steel with manganese and silicon in the ranges specified promotes the desired toughness, hardenability, and ductility in the as-heat treated pipe molds. Two trials of three variations of 0303 (Khare V) steel test bars 2½ OD×21″ long were forged and tested for properties. The chemical analysis of the six heats of the 0303 (Khare V) steel melted were as follows in Table 4: TABLE 4 Varia- % % tion % C Mn % P % S % Si % Ni % Cr Mo % V K2038 0.16 1.49 0.006 0.005 1.29 0.36 1.03 0.26 0.06 K2039 0.21 1.45 0.006 0.004 1.25 0.35 1.01 0.26 0.06

[0012] The forged 0303 (Khare V) steel was prepared and heat treated as follows. For the K2038 melt, the steel was austentized at 1650° F. for 2 hours, water quenched, and tempered at 1150° F. for 2 hours. For the K2039 melt, the steel was normalized at 1650° F. for 2 hours, austentized at 1600° F. for 2 hours, water quenched, and tempered at 1200° F. for 2 hours. The steel was then tested for mechanical properties. The mechanical properties of the 0303 (Khare V) steel are set forth in Table 5, below. TABLE 5 C-V-N Impacts Tensile .2% Yield (Foot Pounds, Variation (ksi) (ksi) % El % RA avg.) K2038 156 143 19 49 35 K2038 147/151 133/138 19/18 59/60 65 K2039 132/136 115/121 23/21 66/65 111

[0013] The carbon level of the steel chemistry of the present invention is lower than in the conventional AISI 4130 range of 0.28-0.33%. Important here, the reduced carbon results in a reduction in hardness and strength coupled with an increase in toughness and ductility in the as-heat treated pipe mold. The reduced carbon also helps reduce the internal stresses of the steel of the present invention. This will mean that there is greater stability after tempering in the pipe molds made from the steel of the present invention. As such, the pipe molds will be less susceptible to quench cracking during the manufacture or due to thermal fatigue, and distortion during production. These combined effects greatly improve the service life.

[0014] Vanadium in the range of 0.03-0.08% is added to the steel of the present invention to give the steel fine austenitic grain size and prevent softening during temper. Vanadium was not included in the AISI 4130 grade of steel. The fine grain size working in conjunction with the low stresses resulting from the use of reduced carbon enhances the stability of the steel of the present invention. Vanadium, along with the alloying elements manganese and molybdenum, helps maintain the desired level of post-temper hardness.

[0015] Manganese in the 1.00-1.50% range provides a high carbon/manganese ratio. Manganese in this range promotes deep hardening at the desired levels without adversely affecting the desired properties of toughness and ductility. This deep hardening is caused by the element manganese very strongly retarding the transformation of austenite. Manganese also lures the transformation temperature, thus, giving the steel fine grain size, with improved yield strength and impact values. As an added benefit, it increases the Pearlite content for the given carbon level, thus, raising strength without sacrificing weldability.

[0016] Silicon provides Solid Solution strengthening and improves high temperature oxidation resistance. Silicon will also counterbalance the possible temper embrittlement effect caused by enhanced manganese.

[0017] The terms and expressions that are used herein are terms of expression and not of limitation. And there is no intention in the use of such terms and expressions of excluding the equivalents of the features shown and described, or portions thereon, it being recognized that various modifications are possible in the scope of the present invention. 

What is claimed is:
 1. A ferritic alloy steel in weight percentage consisting essentially of from about 0.16-0.22% carbon, 1.00-1.50% manganese, 1.15-1.45% silicon, 0.015% maximum phosphorus, 0.015% maximum sulfur, 0.80-1.10% chromium, 0.20-0.30% molybdenum, 0.50% maximum nickel, 0.03-0.08% vanadium, and balance essentially iron.
 2. The steel recited in claim 1, consisting essentially of from about 0.16-0.22% carbon, 1.40-1.50% manganese, 1.20-1.30% silicon, 0.015% maximum phosphorus, 0.015% maximum sulfur, 0.90-1.05% chromium, 0.20-0.30% molybdenum, 0.50% maximum nickel, 0.03-0.08% vanadium, and balance essentially iron.
 3. The steel recited in claim 2, consisting essentially of from about 0.16% carbon, 1.49% manganese, 1.29% silicon, 0.006% phosphorus, 0.005% sulfur, 1.03% chromium, 0.26% molybdenum, 0.36% nickel, 0.06% vanadium, and balance essentially iron.
 4. The steel recited in claim 2, consisting essentially of from about 0.21% carbon, 1.45% manganese, 1.25% silicon, 0.006% phosphorus, 0.004% sulfur, 1.01% chromium, 0.26% molybdenum, 0.35% nickel, 0.06% vanadium, and balance essentially iron.
 5. The steel recited in claim 2, consisting essentially of from about 0.18% carbon, 1.25% manganese, 1.25% silicon, 0.005% maximum phosphorus, 0.005% maximum sulfur, 0.90% chromium, 0.25% molybdenum, 0.30% nickel, 0.05% vanadium, and balance essentially iron.
 6. A pipe mold steel for centrifugally casting pipe formed from a ferritic alloy steel in weight percentage consisting essentially of from about 0.16-0.22% carbon, 1.00-1.50% manganese, 1.15-1.45% silicon, 0.015% maximum phosphorus, 0.015% maximum sulfur, 0.80-1.10% chromium, 0.20-0.30% molybdenum, 0.50% maximum nickel, 0.03-0.08% vanadium, and balance essentially iron.
 7. The pipe mold steel recited in claim 6, consisting essentially of from about 0.16-0.22% carbon, 1.40-1.50% manganese, 1.20-1.30% silicon, 0.015% maximum phosphorus, 0.015% maximum sulfur, 0.90-1.05% chromium, 0.20-0.30% molybdenum, 0.50% maximum nickel, 0.03-0.08% vanadium, and balance essentially iron.
 8. The pipe mold steel recited in claim 7, consisting essentially of from about 0.16% carbon, 1.49% manganese, 1.29% silicon, 0.006% phosphorus, 0.005% sulfur, 1.03% chromium, 0.26% molybdenum, 0.36% nickel, 0.06% vanadium, and balance essentially iron.
 9. The steel recited in claim 7, consisting essentially of from about 0.21% carbon, 1.45% manganese, 1.25% silicon, 0.006% phosphorus, 0.004% sulfur, 1.01% chromium, 0.26% molybdenum, 0.35% nickel, 0.06% vanadium, and balance essentially iron.
 10. The pipe mold steel recited in claim 7, consisting essentially of from about 0.18% carbon, 1.25% manganese, 1.25% silicon, 0.005% maximum phosphorus, 0.005% maximum sulfur, 0.90% chromium, 0.25% molybdenum, 0.30% nickel, 0.05% vanadium, and balance essentially iron.
 11. A pipe mold steel for centrifugally casting pipe formed from a ferritic alloy steel comprising vanadium.
 12. The pipe mold steel recited in claim 11 comprising vanadium in a weight percentage of from about 0.03-0.08%.
 13. The pipe mold steel recited in claim 11 comprising vanadium in a weight percentage of from about 0.06%.
 14. The pipe mold steel recited in claim 11 comprising vanadium in a weight percentage of from about 0.05%. 